Floating Liquid Material Distribution Device

ABSTRACT

A floating liquid material distribution device having a plurality of apertures arranged in a grid pattern is disclosed. The device floats on top of liquid material within a container. When a person applies force to the device with an applicator, the device allows liquid material to be evenly distributed through the apertures to the application surface of the device and onto the applicator. As the liquid material is used up, the device follows the top of the surface of the liquid, and thus follows the liquid material to the bottom of the container, always a distance off the paint. Also disclosed is an actuation device that works in combination with a container lid. When the actuation device is actuated, a liquid material distribution device drops down onto liquid contained within the container.

This application claims the benefit of U.S. Provisional Application No. 62/283,927, filed Sep. 16, 2015, the entire disclosure of which is herein incorporated by reference.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to distributing liquid materials onto an application device and application devices for applying the liquid materials to various surfaces.

BACKGROUND OF THE INVENTION

When applying a liquid material using a container (e.g., a bucket) without the liquid material accessories described by the present invention, a person will dip a roller or brush or other implement into a bucket or a pan filled with a liquid, then possibly wipe the applicator or implement on some other surface to remove the liquid to achieve a desired application quantity on the implement. The problem with using a container such as a paint pan or a bucket with a grid or bucket is that it usually has a single preferred rolling axis. That makes it difficult to apply and remove the liquid material to an apparatus such as a paint roller from any angle. Another problem is that the application device may come in contact with dry liquid. Also, when using a container, such as a bucket, bucket with grid, or a paint pan, transferring the liquid material on the applicator to the end surface can be messy, with the excess liquid dripping from the applicator and down the sides of the container and getting on the hands of the person/worker, not to mention other surfaces where the person/worker is (though these are usually covered with cloths or tarps, in process). Cleaning during application of liquid materials and afterwards is also time consuming. Prior to this invention, for application of liquid material, a person would submerge or dip the applicator such as a paint roller into the liquid material, or alternatively attempt to use a rectangular grid device (or paint pan) that attempts to remove excess liquid material from the applicator.

This invention describes a floating device for distributing liquid material onto an application device that may optionally be part of a container. Whether part of a container or not, in operation, it floats on top of the liquid material in a container (e.g., a five gallon bucket). Such a device helps distribute a quantity of the liquid material evenly on an application device (e.g., brush, roller, etc.). The device floats on the liquid material and can be accessed from any direction, horizontal or vertical, around the liquid material supply container with an application device. When using an application device such as a brush or roller a person/worker will apply force to the device opposing the buoyancy of the floating device allowing the liquid to flow up through the apertures of the device. As the liquid material is consumed, the floating device follows the surface of the liquid material to the bottom of the container. When in use, the applicator is removed, and the liquid material drains back through the apertures and sides of the device back into the liquid material supply. The liquid is forced up through the holes of the device in a controlled volume and is collected onto the applicator without oversaturation.

This invention overcomes many problems in the prior art. U.S. Pat. No. 7,900,313 to Wren describes and claims a buoyant coating contacting member including at least one aperture disposed substantially horizontally within a lidable container for painting. International Publication No. WO2008084328A1 to Hahn describes a buoyant coating contacting member including at least one aperture disposed substantially horizontally within a lidded container. Wren and Hahn (together or separately) do not describe the features of the present invention, namely an apparatus to facilitate the distribution of liquid material onto an application comprising a floating application surface that has, in one aspect, a two-piece construction with first, a plurality of apertures arranged in a grid pattern, and second, a buoyant material such as a closed cell foam float ring that attaches to the bottom horizontal surface of the device. The buoyant material causes the horizontal working surface of the apparatus to float above the liquid material contained within a container. Wren and Hahn also do not disclose a floating liquid material distribution device having, in a second aspect, a one-piece injection molded construction or other design that as a whole is shaped like the first aspect, but wherein a hollow space (instead of foam) causes the apparatus to float on top of liquid material contained within a container. Finally, Wren and Hahn do not disclose a pop lid and an actuation device such that when the device is actuated (e.g., when the lid is first opened), the floating liquid material distribution device drops down onto liquid material that is contained within a container or is removed from the container and placed into the container.

SUMMARY OF THE INVENTION

This invention describes a floating device for distributing liquid material onto an application device that may optionally be part of a container. This floating device comprises a plurality of apertures on its surface arranged in a pattern. The size of the apertures may vary depending on the viscosity of the liquid in use. The device floats on top of the liquid material and the design of the device can be made to fit in containers of various sizes. The device is used to distribute liquid material evenly on an application device such as a brush or roller (e.g., a nine inch paint roller) for applying the liquid material to a surface. The device floats on the liquid material. A person/worker rolls applies force with the applicator on the top surface of the device from any horizontal or vertical direction. When doing this, liquid material seeps through the apertures such that the device distributes liquid material evenly on the applicator. The device floats on the liquid material, and eventually migrates to the bottom of the container as the liquid material is consumed. The device sits a small distance (approximately a half inch) off the liquid material, such that a person/worker applies a force opposing the buoyancy to force the liquid material through the apertures of the floating device for distribution onto the application device. Persons or workers (e.g., painters or anyone who paints) can use this invention.

This invention solves the problem of being able to apply liquid material to an application device from any direction (horizontal and vertical) around a container. As the device floats in the container, and particularly if stored in the container with the liquid material, the floating device stays wet with liquid material. Use of the apparatus is clean and leaves no mess.

There are several objects and advantages of the invention that can be enumerated as follows:

-   -   1) One-piece design: no assembly required.     -   2) Easy to use: when the liquid material container is opened and         mixed, the person/worker just has to place the device on top of         the liquid material. Then the person/worker is ready to start         their application process with an applicator.     -   3) No mess: there is no need to pour liquid material into a         separate pan or spare container. If a person/worker were to use         an older type of flat grid, several gallons of liquid material         must be emptied from a full pail to be able to use a flat grid.     -   4) Easy to load applicator: a person/worker just applies         pressure down with the applicator on the device, and the liquid         material will flow through apertures. The person/worker controls         the amount of liquid material being loaded onto the applicator.         By pressing harder on one side of the applicator the         person/worker can load more liquid material on that side for         controlled material distribution on the applicator.     -   5) Saves money: labor expenses are costly. Using an older type         of grid, the applicator would be over loaded and then the grid         or pan is used to unload excess liquid material from the         applicator. This can take many repetitions (e.g., strokes) and         increases the time spent on a project.     -   6) Cleaner application: having the proper amount of liquid         material on an applicator makes applying liquid material more         efficient. By using this invention, there is very little excess         liquid material on the ends of the applicator, which keeps an         applicator from dripping excess liquid material and prevents         excess material lines when applying liquid material to the         surface being coated.     -   7) Omni directional access: this invention allows the liquid         material container to be used on uneven surfaces. An applicator         can be loaded from any direction around the container. When         using an old type grid, the person/worker needed to be on the         grid side of the container or pan (i.e., paint pan) to access         the grid to be able to unload excess liquid after overloading         the applicator. This means either walking around to the other         side of the container or turning or kicking the container to         line it up for use. Also, with this new device, the applicator         can be loaded from long distances (8′ to over 16′) with the         person/worker on a ladder/scaffold and the container on the         ground or a lower elevation. By using this invention, a         controlled amount of liquid material is being loaded onto the         applicator and not overloaded and stroked off.     -   8) Less liquid material contaminants: when using an old type         flat grid, the liquid material dries out at the top of grid, and         when dried liquid material gets on the applicator it can be         transferred to the surface where the liquid is being applied. In         the present invention, the floating liquid material distribution         device helps to prevent liquid material from drying out.     -   9) Equipment production time: when using an old type of flat         grid, the applicator is constantly being overloaded and becomes         saturated and must be cleaned often. The grid of the present         invention applies only the needed amount of liquid material thus         keeping the applicator aerated and cleaner much longer.     -   10) Shorter start time: if ceasing work operations for any         reason, a person/worker may leave the floating liquid material         distribution device in the container and close the lid. The         device will stay wet and be ready when the person/worker reopens         the lid. In contrast, an old type of grid must be put into place         in the container, and the top of the grid will not be wet and         tends to have dry liquid material when the lid is reopened.         Also, when using a pan (e.g., paint pan), if unused for any         period of time, whether covered or not, the liquid material         tends to dry out.     -   11) Easier clean up: a person worker can either leave the         floating liquid material distribution device in the container         for future use or remove it and wash it off with other         equipment. Since it is always wet, liquid material rinses right         off. An old type of grid or pan must be scraped of dry liquid         material or discarded.

In another aspect of the invention, the floating liquid material distribution device will fit into the top of the lid of a container. A tab or pin is actuated (e.g., pulled) and then the device will fall into the container without generating a mess. This tab or pin can be triggered by the first opening of the lid of the container itself.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a 10″ diameter round design of a floating liquid material distribution device.

FIG. 2 is a side cross-sectional view of a 10″ diameter round design of a floating liquid material distribution device.

FIG. 3 is an alternative embodiment of the 10″ diameter round design of a floating liquid material distribution device.

DETAILED DESCRIPTION OF INVENTION

Persons of skill in the art of applying liquid material (e.g., painters) will recognize the teachings of this invention to be applicable for the application of any type of liquid material (e.g., paint, sealers, lubricants, solvents, etc.).

In brief summary, most prior liquid material grids or pans operated on a principle of overloading an applicator with liquid. Then the person/worker uses the grid, pan, or other surface to remove overloaded liquid material until the desired application amount is reached. The present invention works in the opposite way, by using a grid of apertures to allow more precise control over the initial application of liquid material to an application device (e.g., a paint roller).

FIG. 1 is a top view of a 10″ in diameter round design of a floating liquid material distribution device. The device can be made of any material, including plastic or metal (tin or steel). In a first embodiment, the shape of the device is 10 inches in diameter. The measurements are 0.75 inches in height (thickness), and 10 inches in diameter. Here the device 100 contains a surface 102 with a plurality of apertures 108 arranged in a grid pattern and a foam float 104. The apertures 108 are of a size that controls the volume of liquid material being distributed when forcing the device 100 into the liquid material. Also, the apertures 108 are sized to accommodate the viscosity of the liquid material being used. Also, the apertures 108 are sized to accommodate the number of apertures 108. The surface 102 can be constructed of any material that will serve the purpose of the invention (e.g., metal, plastic, glass, etc.). The surface 102 has two sides. The apertures 108 are sized so that liquid material of conventional density may easily seep through the apertures when the floating device is depressed into the liquid material surface. The foam float 104 is a two-piece double material. To improve buoyancy, a closed cell foam is used for the foam float 104. Foam float 104 is fixed (e.g., adhered) to the “down” side of surface 102 in an annular fashion, to create a ring (item 104 in FIG. 2) of buoyant material which causes the whole of the device 100 to float on liquid material. Liquid material seeps up through the inside of the ring. Thus, when the device 100 is placed in a container with the float 104 side down, the device floats on top of liquid material in the container. When an applicator is applied on the device, liquid material is applied evenly and controllably on the applicator. The device floats on the liquid material and moves when the applicator is applied to the device 100. The device along the other side of the surface 102 may also include small bumps (not shown) which may aerate an applicator that is receiving a supply of liquid material through the nearby apertures as the applicator moves over the surface of the liquid material distribution device. As the liquid material is used up/consumed, the device follows the top of the surface of the liquid, and thus follows the liquid material to the bottom of the container, always a distance off the paint.

In an alternative embodiment, the foam float 104 can be constructed as part of a one-piece injection molded unit to create a hollow space volume. In this aspect, the overall device 100 will appear to be the same shape and volume as the first embodiment. However, rather than closed cell foam affixed in a ring to create the buoyancy, device 100 as a whole (with the hollow annular volume in the same general place where the foam ring would otherwise be) is less dense than the liquid material. In this round embodiment, the surface of the device has a first radius.

In both round embodiments, the device 100 can be constructed to accommodate any shape of container. Moreover, the floating liquid material distribution device 100 may be sized to fit into the top of the lid of a container. This enables deployment of another feature. Optionally, a conventional liquid container lid may be fitted with a tab or pin (not shown) which is actuated (e.g., pulled), causing the device to fall/drop into the container without generating a mess. In this case there is a pop lid holding the liquid material distribution device, and the pop lid is coupled to the actuation device.

FIG. 2 is a side cross-sectional view of a 10″ diameter round design of a floating liquid material distribution device, showing the surface 102 and four foam float rings 104. The overall measurements of the device in this embodiment are the same as those in FIG. 1: 0.75 inches in height (thickness), and 10 inches in diameter. In one embodiment, the ring 104 is of closed cell foam and it is affixed to one side of the surface 102 at the surface's edge so as to create a cylindrical volume of space within the ring 104, whereby the ring 104 causes the device to float on top of liquid material contained within a container. In another embodiment, the ring is disposed at the edge of the circular surface and extending axially therefrom, the ring defined by the volume between two imaginary concentric cylinders of the same height but different radii, wherein the difference between the different radii is in the range of ten to twenty-five percent of the first radius, the volume within the ring is hollow, and the surface and the ring together comprise a single unitary piece of injection molded material.

FIG. 3 is an alternative embodiment of the 10″ diameter round design of a floating liquid material distribution device. In this case, the surface 202 of the device comprises circular apertures 208 rather than rectangular apertures. The surface 202 can be constructed of any material that will serve the purpose of the invention (e.g., metal, plastic, glass, etc.). The apertures 208 are of a size that controls the volume of liquid material being distributed when forcing the device 200 into the liquid material. Also, the apertures 208 are sized to accommodate the viscosity of the liquid material being used. Also, the apertures 208 are sized to accommodate the number of apertures 208. This embodiment of the device 200 also has a foam float 204 and also shares the same properties as the embodiment discussed in FIG. 1. In particular: the foam float 204 is a two-piece double material. To improve buoyancy, a closed cell foam is used for the foam float 204. When the device 200 is placed in a liquid container, the device floats on top of liquid material in the container. When an applicator is forced into and moved across the surface the device (i.e., applied to the device), liquid material is applied evenly on the applicator. The device floats on the liquid material. An application is applied to the device 200. The device follows the top of the surface of the liquid, and thus follows the liquid material to the bottom of the container, always a distance off the paint. Alternatively, as mentioned before, the foam float 204 can be a one-piece injection molding to create a hollow space volume. Here the device 200 is circularly lidded to accommodate any shape of container and not just any paint pan. Moreover, the floating liquid material distribution device surface 200 will fit into the top of the lid of a container. Another potential feature is to include a tab or pin (not shown) which is actuated (e.g., pulled), causing the device to fall/drop into the container without generating a mess. In this case there is a pop lid holding the floating liquid material distribution device, and the pop lid is coupled to the actuation device. The foam float 204 also may include bumps which serve to aerate an applicator that is receiving an distribution of liquid material through a nearby aperture as the applicator moves over the surface of the liquid material distribution device.

While the above specification and examples provide a description of the invention, many embodiments of the invention can be made (for example, the liquid material distribution device does not have to be circular or round) without departing from the spirit and scope of the invention. It is to be understood that the foregoing embodiments are provided as illustrative only, and does not limit or define the scope of the invention. Various other embodiments are also within the scope of the claims. 

What is claimed is:
 1. An apparatus for the application of liquid material, comprising: a application surface having a plurality of apertures arranged in a grid pattern, the surface having two sides, the surface having a first perimeter to match the shape of a container; a ring of closed cell foam affixed to one side of the surface at the surface's edge so as to create a cylindrical volume of space within the ring, whereby the ring causes the apparatus to float on top of liquid material contained within a container; and an amount of space between the ring and the surface to define the extent of the cylindrical volume.
 2. The apparatus of claim 1, further comprising a plurality of bumps along the other side of the surface, whereby the respective bumps may aerate an applicator that is receiving a supply of liquid material through the nearby apertures as the applicator moves over the surface of the apparatus.
 3. The apparatus of claim 1, wherein the apertures are of a size that controls the volume of liquid material being distributed when forcing the apparatus into the liquid material.
 4. The apparatus of claim 1, wherein the apertures are sized to accommodate the viscosity of the liquid material being used.
 5. The apparatus of claim 1, wherein the apertures are sized depending on the number of apertures.
 6. The apparatus of claim 1, wherein the grid is a radio grid.
 7. The apparatus of claim 1, wherein the apparatus is sized to cover nearly all of the top liquid material surface inside the container from the top of the container to the bottom of the container.
 8. An apparatus for the application of liquid material, comprising, in a single-piece construction: a floating application surface having a plurality of apertures arranged in a grid pattern on the surface, the surface having a first perimeter to match the shape of a container; a ring having hollow volume disposed at the edge of the surface and extending axially therefrom, the shape of the ring depending on the shape of the container; wherein the surface and the ring together comprise a single unitary piece of injection molded material.
 9. The apparatus of claim 8, further comprising a plurality of bumps along the side of the surface opposite the ring, whereby the respective bumps may aerate an applicator that is receiving a supply of liquid material through the nearby apertures as the applicator moves over the surface of the apparatus.
 10. The apparatus of claim 8, wherein the apertures are of a size that controls the volume of liquid material being distributed when forcing the apparatus into the liquid material.
 11. The apparatus of claim 8, wherein the apertures are sized to accommodate the viscosity of the liquid material being used.
 12. The apparatus of claim 8, wherein the apertures are sized depending on the number of apertures.
 13. The apparatus of claim 8, wherein the apparatus is sized to cover nearly all of the top liquid material surface inside the container from the top of the container to the bottom of the container.
 14. A liquid material container comprising: a liquid material distribution apparatus part comprising a floating application surface having a plurality of apertures arranged in a grid pattern, a foam float ring that attaches to the bottom surface which causes the apparatus to float on top of liquid material contained within the container and defines an amount of space between the apparatus and the liquid material; a pop lid holding the liquid material distribution apparatus, the pop lid coupled to an actuation device such that when the device is actuated, the liquid material distribution apparatus drops down into liquid material that is contained within the container.
 15. The apparatus of claim 14, further comprising a plurality of bumps along the side of the surface opposite the ring, whereby the respective bumps may aerate an applicator that is receiving a supply of liquid material through the nearby apertures as the applicator moves over the surface of the liquid material distribution apparatus. 